Multipurpose membrane for containers

ABSTRACT

A membrane for use with a container is provided herein. The membrane comprises a first layer comprising a peripheral area defined by a first perimeter of the first layer, and a first line of weakness formed inward of the first perimeter. The first line of weakness defines a flap. The membrane further comprises a second layer comprising a peripheral zone defined by a second perimeter of the second layer and a second line of weakness formed inward of the second perimeter. The second line of weakness defines a central portion. The membrane further comprises a first seal area comprising at least a portion of the peripheral zone of the second layer being adhered to at least a portion of the peripheral area of the first seal area.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit of provisional European Application No. 22305087, entitled “MULTIPURPOSE MEMBRANE FOR CONTAINERS,” filed Jan. 27, 2022; and provisional European Application No. 22305462, entitled “MULTIPURPOSE MEMBRANE FOR CONTAINERS,” filed Apr. 6, 2022, which are each incorporated herein in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to container closures, particularly to paper-based membranes designed to retain freshness of goods within the container and provide tamper evident features.

BACKGROUND OF THE DISCLOSURE

In many containers used to package dispensable products such as seasonings, spices, bite-sized snacks or other food items, a plastic dispenser is used to provide dispensing control for the container. There are many countries and regions implementing legislation which requires reducing the amount of plastic in these types of containers. Generally, even in composite and/or paper-based containers when the vast majority of the container itself is free of plastic, the plastic-based dispenser exceeds the amount of plastic permitted by legislation.

Through ingenuity and hard work, the inventors have developed systems and methods for making a paper membrane which is recyclable in a curbside stream, allows for controlled dispensing of products therethrough, is easy to manufacture and use, and reduces the overall amount of plastic present in the container system.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates generally to a paper or cardboard membrane for separating a consumable product from the outside environment. The membrane may be configured as a dispenser for the product and may provide a tamper evident feature.

In an example embodiment of the present invention, a membrane for use with a container is provided. The membrane may comprise a first layer comprising a peripheral area. The peripheral area may be defined by a first perimeter of the first layer, and a first line of weakness formed inward of the first perimeter. The first line of weakness may define a flap. The membrane may further comprise a second layer comprising a peripheral zone. The peripheral zone may be defined by a second perimeter of the second layer and a second line of weakness formed inward of the second perimeter. The second line of weakness may define a central portion. The membrane may comprise a first seal area. At least a portion of the peripheral zone of the second layer may be adhered to at least a portion of the peripheral area of the first layer in the first seal area.

In some embodiments, the first layer may define a first shape and the second layer may define a second shape. In some embodiments, the first shape and the second shape are the same. In some embodiments, the first shape and the second shaper are different.

In some embodiments, the first layer and the second layer are formed from one of paper or cardboard.

In some embodiments, the membrane further comprises a hinge formed within the first line of weakness. In some embodiments, the seal area may form a hermetic seal between the first layer and the second layer. In some embodiments, the first seal area may be disposed between the perimeter of the first layer and the first line of weakness of the first layer. In some embodiments, the first seal area may be disposed between the second perimeter of the second layer and the first line of weakness.

In some embodiments, the membrane, additionally comprises a second seal area. The second seal area may be disposed between the second line of weakness of the second layer and the first line of weakness of the first layer. In some embodiments, the second seal area may comprise a peelable adhesive. In some embodiments, the second seal area may comprise a pressure sensitive adhesive. In some embodiments, the first seal area may comprise a permanent adhesive. In some embodiments, the first seal area and the second seal area may be formed with the same type of adhesive. In some embodiments, the first seal area and the second seal area may be formed with different adhesives.

In some embodiments, the flap of the first layer may further comprise a pull tab. In some embodiments, the pull tab may comprise a portion of the flap which is folded and configured to extend out of the plane of the first layer. In some embodiments, the flap may be resealable to the peripheral zone.

In some embodiments, the second layer may further comprise at least one opening disposed within the central portion. In some embodiments, the at least one opening may comprise a plurality of openings. In some embodiments, the at least one opening may be a first opening and a second opening, wherein the first opening and the second opening are different sizes.

In another embodiment of the present invention a package is provided. In some embodiments, the package comprises a body defining a top end and an internal wall, a lid configured to be received by the top end of the body, and a membrane adhered to the body. The membrane may comprise a first layer comprising a peripheral area. The peripheral area may be defined by a first perimeter of the first layer, and a first line of weakness formed inward of the first perimeter. The first line of weakness may define a flap. The membrane may additionally comprise a second layer comprising a peripheral zone. The peripheral zone may be defined by a second perimeter of the second layer and a second line of weakness formed inward of the second perimeter. The second line of weakness may define a central portion. The central portion may comprise an opening. The membrane may include a first seal area, wherein at least a portion of the peripheral zone of the second layer is adhered to at least a portion of the peripheral area of the first layer in the first seal area.

In some embodiments, at least the first layer of the membrane may be recessed within the internal wall. In some embodiments, the internal wall may further comprise an inner liner, sealant layer or coating. In some embodiments, the seal area may form a hermetic seal between the first layer and the second layer. In some embodiments, the membrane may be adhered to the internal wall of the body. In some embodiments, the membrane may be adhered to a rim circumscribing the top end of the body. In some embodiments, the lid may be hingedly attached to the body. In some embodiments, the lid may be rotatably attached to the body. In some embodiments, the lid may comprise a port, such that when rotated the port aligns with the opening in the second layer of the membrane.

In yet another embodiment of the present invention a package is provided. The package comprises a body defining a top end, and a membrane adhered to an inner surface of the body. The membrane may comprise a first layer comprising a peripheral area. The peripheral area may be defined by a first perimeter of the first layer, and a first line of weakness formed inward of the first perimeter. The first line of weakness may define a flap. The membrane may further comprise a second layer comprising a peripheral zone. The peripheral zone may be defined by a second perimeter of the second layer and a second line of weakness formed inward of the second perimeter. The second line of weakness may define a central portion, wherein the central portion comprises an opening. The central portion may further include a first seal area, such that at least a portion of the peripheral zone of the second layer is adhered to at least a portion of the peripheral area of the first layer in the first seal area.

In some embodiments, the top end of the body may be folded inward, toward a central axis of the body, to form a rim. In some embodiments, the flap may comprise a pull tab configured to tuck under the rim of the body in a reclosed position of the flap. In some embodiments, the pull tab may comprise a through cut sized and configured to receive a finger for opening of the flap.

BRIEF DESCRIPTIONS OF THE SEVERAL VIEWS OF THE DRAWING(S)

A full and enabling disclosure directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended drawings, in which:

FIG. 1A illustrates a bottom view of a membrane, in accordance with some embodiments of the present disclosure;

FIG. 1B illustrates a top view of a membrane, in accordance with some embodiments of the present disclosure;

FIG. 2A illustrates a top view of a first layer of the membrane shown in FIG. 1A, in accordance with some embodiments of the present disclosure;

FIG. 2B illustrates a bottom view of a first layer of the membrane shown in FIG. 1A, in accordance with some embodiments of the present disclosure;

FIG. 3 illustrates a top view of a second layer of the membrane shown in FIG. 1A, in accordance with some embodiments of the present disclosure;

FIGS. 4A-D illustrate top views of a membrane, in accordance with some embodiments of the present disclosure;

FIG. 5 illustrates a front view of a welding device used to form the membrane illustrated in FIG. 1A, in accordance with some embodiments of the present disclosure;

FIGS. 6A-B illustrate perspective views of a container using the membrane shown in FIG. 1A, in accordance with some embodiments of the present disclosure;

FIGS. 7A-D illustrate perspective views of a container using the membrane shown in FIG. 1A, in accordance with some embodiments of the present disclosure;

FIG. 8A-E illustrate a perspective view of opening and closing of a flap of the membrane shown in FIG. 1A, in accordance with some embodiments of the present disclosure;

FIG. 9 illustrates example configurations of openings within the membrane shown in FIG. 1A, in accordance with some embodiments of the present disclosure;

FIGS. 10A-F illustrate perspective views of the container using the membrane shown in FIG. 1A, in accordance with some embodiments of the present disclosure;

FIGS. 11A-C illustrate perspective views of an example embodiment of the example membrane shown in FIG. 1A adhered to an example container, in accordance with some embodiments of the present disclosure;

FIGS. 12A-D illustrate perspective views of an example embodiment of the example membrane shown in FIG. 1A adhered to an example container, in accordance with some embodiments of the present disclosure;

FIGS. 13A-D illustrate an example embodiment of the membrane shown in FIG. 1A adhered to an example container, in accordance with some embodiments of the present disclosure; and

FIGS. 14A-D illustrates an example container system utilizing a membrane, in accordance with some embodiments of the present disclosure.

Repeated use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present disclosure.

DETAILED DISCLOSURE

Reference will now be made in detail to embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the present disclosure, not limitation of the present disclosure. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present disclosure without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIGS. 1A-B illustrate a multipurpose membrane 100 for use within a container system. In some embodiments, the container comprises a paper-based, cardboard-based, or composite container. In some embodiments, the container may use recycled paper and/or cardboard, virgin paper or cardboard, or a combination of recycled and virgin paper and/or cardboard. In an embodiment, the container system may comprise a container, a membrane, and a lid. In some cases, the lid may be removeable and, optionally, replaceable onto the container. In some embodiments, the lid may be paper-based, cardboard-based, plastic-based, pulp paper-based or a composite. In an embodiment, the membrane 100 provides a hermetic seal prior to initial opening of the container. In some embodiments, the membrane remains hermetically sealed to the container when the lid is removed from the container, until the initial opening of the membrane 100.

In some embodiments, the multipurpose membrane 100 comprises a first layer 110 and a second layer 120. In some embodiments, the first layer 110 may have a first perimeter 111 defining a first shape, and the second layer 120 may have a second perimeter 121 defining a second shape. In some embodiments, the first shape and the second shape are the same shape (e.g., both circles, squares, triangles, or irregular shape), while in other embodiments, the first shape and the second shape are different.

In some embodiments, the first perimeter 111 is larger than the second perimeter 121 corresponding to the first shape being larger than the second shape, while in some embodiments the first perimeter 111 and the second perimeter 121 may be equal (i.e., the first layer 110 and the second layer 120 are the same size). In some embodiments, the first layer 110 and the second layer 120 may form concentric shapes, while in other embodiments the first layer 110 and the second layer 120 may be coaxial shapes.

In some embodiments, the first layer 110 and the second layer 120 of the membrane 100 may be separable from one another. The first layer 110 may define a first line of weakness 112 disposed inward of the first perimeter 111. The first line of weakness 112 may take any form which may ease breaking the layer for example, in some embodiments, the first line of weakness 112 may extend partially through the first layer 110, while in other embodiments, the first line of weakness 112 may define a series of perforations through the first layer 110. In still other embodiments, the line of weakness 112 may comprise a throughcut through the first layer 110 that circumscribes the majority of the desired opening.

FIGS. 2A-B illustrate the first layer 110 of the membrane 100. In some embodiments, the first line of weakness 112 may define a flap 116 and a peripheral area 115. In some embodiments, the first line of weakness 112 may be circular, triangular, or may be an irregular shape. The flap 116 may be internal to the first line of weakness 112, while the peripheral area 115 may extend between the first perimeter 111 and the first line of weakness 112. In some embodiments, the first line of weakness 121 may form a closed shape such that the flap 116 is removable from the peripheral area 115 of the first layer 110, while in some embodiments, the flap 116 may remain attached to the peripheral area 115 by a hinge 112 b, wherein the first line of weakness 112 is discontinuous about the hinge 112 b. In some embodiments, the hinge 112 b is sized and configured such that it can be torn through upon opening of the flap 116.

The flap 116 may be circular, triangular, or other shape, in some embodiments, the shape of the flap 116 may correspond to the product to be dispensed. In some embodiments, the first line of weakness 112 may be concentric or coaxial with the first perimeter 111, while in other embodiments, the first line of weakness 112 may be eccentric with respect to the first perimeter 111. In some embodiments, the flap 116 may be the same shape as the first layer 110, while in other embodiment the flap 116 may define a different shape than the first layer 110.

In some embodiments, the flap 116 may be removable from the first layer 100. In some embodiments, the flap 116 may include a pull tab 114. In an embodiment, the pull tab is defined by a portion 112 a of the first line of weakness 112 and a groove or crease 113 formed within the first layer 100. In some embodiments, the crease 113 may be formed along a chord of the flap 116, wherein the chord is a line segment connecting two end points of a perimeter that does not pass through the center of the shape. In some embodiments, the portion 112 a of the first line of weakness 112 may be a throughcut of the first layer such that the pull tab 114 is moveable from the peripheral area 115 of the first layer 110 upon formation of the crease 113.

In some embodiments, the pull tab 114 may extend out of the plane of the first layer 110 such that the pull tab 114 is easily graspable, for example, folded back upon itself. The pull tab 114 may be maneuvered to rupture the first line of weakness 112 or hinge 112 b to separate the flap 116 from the peripheral area 115. In some embodiments, the first line of weakness 112 may form a closed shape such that the pull tab 114 and flap 116 may be detached from the peripheral area 115 and may be removed from the first layer 110, and the membrane 100 completely.

In some embodiments, the flap 116 may remain attached to the peripheral area 115 by the hinge 112 b formed within the first line of weakness 112. In some embodiments, the hinge 112 b may be formed along the first line of weakness 112 opposite the portion 112 a defining the pull tab 114, while in other embodiments, the hinge 112 b may be formed at any point along the first line of weakness 112. In some embodiments, the hinge 112 b may be sized and configured such that the flap 116 is not easily severable from the peripheral area 115 when the pull tab 114 is lifted.

The hinge 112 b may allow the flap 116 to provide access to the second layer 120, and thereby in some embodiments, access to the product within the container system. In this embodiment, the flap 116 may be removed from and replaced on the second layer 120. In some embodiments, the bottom surface of the flap 116 or the top surface of the second layer 120 may be patterned with a pressure sensitive adhesive. The pressure sensitive adhesive may retain the seal of the membrane 100 when the flap 116 is replaced on the second layer 120 within the plane of the membrane 100.

In some embodiments, the first line of weakness 112 may be configured as a tamper evident feature. For example, in an embodiment, the first line of weakness 112 may rupture as the flap 116 is removed. Upon removal, or first opening the flap 116 may be removed, or configured such that the flap 116 will not reseal in the exact location to align with the peripheral area 115, such that the first line of weakness 112 is visibly shifted.

In some embodiments, the pull tab 114 may be formed within the first layer 110 prior to application of the second layer 120. After formation of the membrane 100, the second layer 120 may be accessible by rupturing the first line of weakness 112 by maneuvering the pull tab 114.

The first layer 110 may be cardboard or paper based. In some embodiments, the first layer 110 may be a single ply layer, while in other embodiments, the first layer 110 may comprise multiple paper, cardboard or a combination of paper and cardboard layers. In some embodiments, the first layer 110 may include a barrier layer. The barrier materials may provide a moisture barrier and/or an oxygen barrier. In some embodiments, the first layer 110 may be coated with a barrier material, for example aluminum, PET, bioplastic, or other barrier known or developed within the art. In some embodiments, one or both sides of the first layer 110 may include a sealant layer or may be coated with a sealant. The sealant may form the barrier properties. In some embodiments the sealant may be polyethylene, a bioplastic, a bio resin, white glue, a combination thereof, or any other sealants known in the art.

In some embodiments, the first layer 110 may define a first diameter D₁ across the first perimeter 111 and may define a second diameter D₂ extending across the first line of weakness 112. The first diameter D₁ may be greater than the second diameter D₂. In some embodiments, the first diameter D₁ is configured to be larger than a diameter of the container, such that a portion of the first layer 110 may be adhered to an interior portion of the container wall, an exterior portion of the container wall or about a rim of the container, to secure the membrane 100 to the container. In some embodiments, the first layer 110 may be recessed within the container wall and adhered thereto. In some embodiments, the container may comprise an inner liner and/or sealant layer or coating, such as polyethylene or any other sealant noted herein or known in the art.

The membrane 100 may include a second layer 120 as illustrated in FIG. 3 . With respect to the container, the second layer 120 may comprise the inner layer of the membrane 100. The second layer 120 may be cardboard or paper based. In some embodiments, the second layer 120 may be a single ply layer, while in other embodiments, the second layer 120 may comprise multiple paper, cardboard or a combination of paper and cardboard layers. The second layer 120 may be defined by the second perimeter 121. In some embodiments, the second perimeter 121 may be circular, triangular, or may be an irregular shape. A second line of weakness 122 may be formed within the second layer 120 defining a central portion 126. The second line of weakness 122 may take any form which may ease breaking the layer for examine, in some embodiments, the second line of weakness 122 may extend partially through the second layer 120, while in other embodiments, the second line of weakness 122 may define a series of perforations through the second layer 120.

In some embodiments, the central portion 126 may be circular, triangular, or may be an irregular shape. In some embodiments, the second line of weakness 122 may be concentric or coaxial with the second perimeter 121, while in other embodiments, the second line of weakness 122 may be eccentric with respect to the second perimeter 121. In some embodiments, the central portion 126 may define the same shape as the second layer 120, while in other embodiment the central portion 126 may define a different shape than the second layer 120.

The second layer 120 may define a peripheral zone 125 extending between the second perimeter 121 and the second inner line of weakness 122. In some embodiments, an adhesive may be patterned applied to the top surface of the second layer 120 within the peripheral zone 125. In some embodiments, the adhesive may be a pressure sensitive adhesive such that the flap 116 may be reseal to the peripheral zone 125 after an initial opening.

The second layer 120 may define a third diameter D₃ extending across the second perimeter 121, and the second line of weakness 122 may define a fourth diameter D₄. The third diameter D₃ may be smaller than the fourth diameter D₄. In some embodiments, the third diameter D₃ of the second layer 120 is smaller than the first diameter D₁ of the first layer 110, while in some embodiments, the third diameter D₃ is equivalent to the first diameter D₁. In some embodiments, the third diameter D₃ is larger than the second diameter D₂ such that when the pull tab 114 is maneuvered to fracture or open the first line of weakness 112, the second layer 120 remains otherwise adhered to the first layer 110.

In some embodiments, the second layer 120 may have one or more openings 124. In an embodiment, the opening 124 may be formed within the central portion 126 of the second layer 120. In some embodiments, the opening 124 may be positioned inward of the second line of weakness 122 (e.g., within the central portion 126), while in other embodiments, the opening 124 may be positioned external thereto (e.g., within the peripheral zone 125). The shape and the size of the opening 124 may correspond to the product to be dispensed from the container.

In some embodiments, the opening 124 may be a plurality of openings within the central portion 126 (see, e.g., FIG. 9 ). For example, the opening 124 may comprise a plurality of smaller openings for dispensing a powdered product, while an opening 124 with a single larger opening may be used for larger sized objects, for example gum, or sugar cubes. In some embodiments, the opening 124 may comprise a grid. In some embodiments, the central portion 126 may include multiple openings. In some embodiments, the second layer 120 may include the opening 124 about the second perimeter 121. In some embodiments, the central portion 126 may include multiple openings, for example a first opening may be configured as a shaker, while a second opening may be configured to receive a spoon or dispense larger quantities of the product, or the product at a higher velocity.

In some embodiments, the central portion 126 may be removed to allow larger products and/or a greater flow of products to be dispensed through the membrane 100. In some embodiments, the central portion 126 may be removed by fracturing the second line of weakness 122. In some embodiments, a second hinge 122 b may disrupt the second line of weakness 122. The second hinge 122 b, may allow the central portion 126 to be maneuvered to allow a greater flow of product from the container, and repositioned in line with the peripheral area 125 to return to the lower flow of product from the container. In some embodiments, the second line of weakness 122 may be formed such that after a fracture, the central portion 126 may readhere to the second layer 120 along the second line of weakness 122.

In some embodiments, the membrane 100 may be configured such that the second layer 120 is product facing. In some embodiments, the second layer 120 may be a single ply layer, while in other embodiments, the second layer 110 may comprise multiple paper or cardboard layers. In some embodiments, the second layer 120 may include a barrier layer. The second layer 120 may be food safe.

FIGS. 4A-D illustrate through cut views of the membrane 100. In some embodiments, illustrated in FIGS. 4A-B the membrane 100 may comprise a first sealing area 130 and a second sealing area 131. An adhesive may be pattern applied to the first layer 110 (or optionally the second layer 120) within the first sealing area 130 and the second sealing area 131. If applied to the first layer 110, the first sealing area 130 may comprise an area interior of and exterior to the second perimeter 121 when the second layer 120 is aligned on the first layer 110. In some embodiments, the first sealing area 130 may be sized to ensure registration and sealing between the first layer 110 and the second perimeter 121. In an embodiment, first sealing area 130 may comprise a permanent seal. In some embodiments, illustrated in FIG. 4A, the second sealing area 131 may be disposed interior of the first line of weakness 112 and exterior of the second line of weakness 122. The second sealing area 131 may provide a secondary seal such that the opening 124 is sealed, preferably hermetically, prior to the flap 116 being opened. In an embodiment, second sealing area 131 may comprise a peelable seal.

In other embodiments, as illustrated in FIG. 4B, the second sealing area 131 may partially overlap with a portion 122 a of the second line of weakness 122 forming the pull tab 114. The overlap may create a hermetic seal when the pull tab 114 is bent or folded out of the plane of the membrane 100, but before the flap 116 is opened.

In some embodiments, the first sealing area 130 may be formed from a pattern application of a first adhesive, and the second sealing area 131 may be formed from a pattern application of a second adhesive. The adhesive may be a permanent adhesive, a pressure sensitive adhesive, or other adhesive used for joining layers. In some embodiments, the first adhesive and the second adhesive are the same type of adhesive, while in other embodiments, the first adhesive and the second adhesive are different types of adhesive. For example, the first adhesive may be a permanent adhesive, and the second adhesive may be a pressure sensitive adhesive to allow peelability of the flap and to allow the flap 116 to reseal to the second layer 120 after opening, while maintaining the structure of the membrane 100. In some embodiments, the same adhesive may be used in first sealing area 130 and second sealing area 131, but greater heat, pressure, or a combination thereof may be applied in the first sealing area 131, to create a stronger seal.

In some embodiments, the second sealing area 131 is configured to maintain the hermetic seal of the membrane, to retain the freshness of and extend the life of the product, within the container.

In some embodiments, as illustrated in FIG. 4C, the membrane 100 may only define one sealing area 132. The one sealing area 132 may extend from the peripheral area 115 of the first layer 110, across the second perimeter 121, and the first line of weakness 111. In some embodiments, the sealing area 132 may be formed with permanent adhesive, while in other embodiments, the sealing area may be formed with a pressure sensitive adhesive.

FIG. 4D illustrates an alternative embodiment, wherein the first layer is configured as the flap. As illustrated, the third diameter D₃, extending across the second perimeter 121 may be larger than the first diameter D₁, extending across the first perimeter 111. In such embodiments the seal area 130 may be formed within the peripheral zone 125 of the second layer 120 between the second line of weakness 122 and the second perimeter 120. The adhesive may be patterned such that the pull tab 114 may be free of adhesive. In some embodiments, the first layer 110 configured as the flap 116 may be resealable to the peripheral zone 125 of the second layer.

In some embodiments, the membrane 100 may be formed utilizing a welding device. The welding device 300, illustrated in FIGS. 5A-B may be configured to apply pressure to the first layer and the second layer within the sealing areas, to form a seal. In some embodiments, the welding device 300 may include a first ridge 340 and a second ridge 341. The number of ridges within the counter welding device 300 may correspond to the number of sealing areas within the membrane.

In some embodiments, the first ridge 340 and the second ridge 341 may be the same height, while in other embodiments, the first ridge 340 and the second ridge 340 may be differing heights. The heights, and/or the height difference between the first ridge 340 and the second ridge 341 may contribute to the amount of pressure applied in the sealing areas.

The welding device 300 may be configured to be received by a die. In some embodiments, the die may be a flat surface such that the ridges 340, 341 may press the layers 110, 120 onto the flat surface to join the first layer 110 and the second layer 120 to one another. In some embodiments, the die may comprise a changing thickness to correspond to ridges 340, 341. In some embodiments, welding device 300 may apply changing force throughout the welding process.

In some embodiments, varying pressure may be applied to the welding device 300 as the counter welding device 300 engages with the die.

In some embodiments, the welding device 300 may be a solid device, wherein the ridges are disposed on a backing 345. In some embodiments, the backing 345 may be configured to minimize the amount of material needed, for example the backing 345 may define openings to reduce the weight of the welding device 300.

Although here a first and second ridge are described any appropriate number of ridges may be used.

In some embodiments, the membrane 100 may be disposed on the interior of a container 200, as illustrated in FIGS. 6A-B, optionally in a recessed manner. In some embodiments, the container may comprise a paper-based container. Notably, the container may be made by methods disclosed within U.S. Pat. No. 9,975,306 entitled Method and Machine for Assembling Rigid Tubular Bodies Made from A Cardboard Material with a Sealing Structure, filed Nov. 27, 2013; and/or U.S. Pat. No. 10,315,377 entitled Method for Assembling Tubular Bodies Made from a Cardboard material with a Sealing Structure, filed Nov. 25, 2014, which are each incorporated by reference herein in their entireties. In an embodiment, the container system may comprise a container, optionally a lid, and the membrane. In an embodiment, the membrane 100 provides a hermetic seal prior to initial opening.

FIG. 6A illustrates the example container 200 in a closed position. The container 200 defines a lid 205 and a body 207. In some embodiments, the lid 205 is recessed into and hingedly attached to the body 207 of the container 200. FIG. 6B illustrates the container 200 in an open position. The lid 205 is pivoted about a pivot point 213 of the body 207 of the container 200. In some embodiments, the lid 205 is completely removable and replaceable on the body 207 of the container 200. Illustrated the open position the membrane 100 may be recessed within the body 207 of the container 200. In some embodiments, the peripheral area 115 of the first layer 110 is adhered to the body 207 of the container 200, while in other embodiments, the peripheral zone 125 of the second layer 120 may be adhered to the body 207 of the container 200.

In some embodiments, the pull tab 114 may be positioned adjacent the pivot point 213 of the container 200, while in other embodiments, the membrane 100 may be oriented such that the pull tab 114 may be positioned opposite the pivot point 213 of the container 200 or towards any point around the body 207 of the container 200.

FIGS. 7A-D illustrate the container system 200 in an example embodiment. FIG. 7A illustrates the container 200 in an open position thereby exposing the membrane 100. The flap may be lifted thereby breaking the seal between the first layer 110 and the second layer 120. Removal of the flap 116 from the central portion 126 exposes the opening 124 and provides access to the contents of the body 207 of the container 200, as illustrated in FIG. 7B. In some embodiments, the lid 205 may be pivoted back onto the body 207 of the container 200 and may seal the opening 124. In some embodiments, the lid 207 may include a barrier layer configured to keep the contents of the container fresh.

FIGS. 7C-D illustrate the removal of the central portion 126 from the second layer 120. In some embodiments, the opening 124 may be too small to dispense the product adequately (e.g., product to large, product dispensing at a slow rate), or may not adequately dispense all of the product from the container. The central portion 126 may be removed by fracturing the second line of weakness 122, (see e.g., FIG. 3 ) thereby yielding an expanded opening 128. In some embodiments, the central portion 126 of the second layer 120 may be removed without removing the flap 116 from the membrane 100 (see e.g., FIG. 8C). In some embodiments, the central portion 126 may be hingedly attached to the peripheral zone 125 such that the membrane 100 may transition between the opening 124 and the expanded opening 128.

FIGS. 8A-E illustrate the container 200 in the open configuration wherein the flap 116 may be removed and replaced on the second layer 120. In some embodiments, the flap 116 may remain attached to the second layer 120 by the hinge 116. In some embodiments, the flap 116 may be releasably sealed to the second layer 120 with an adhesive. The adhesive may be a pressure sensitive adhesive disposed about the peripheral zone 125. The pressure sensitive adhesive may be configured such that the flap 116 may be removed and replaced up to 100 times, up to 150 times or even up to 200 times. In some embodiments, the flap 116 may be resecured to the peripheral zone 125 before the lid 205 is replaced in the closed position. While in some embodiments, the pressure from replacing the lid 205 on to the body 207 of the container 200, as illustrated in FIG. 8E, may reseal the flap 116 to the second layer 120.

FIG. 9 illustrates a plurality of configurations of the second layer 120 of the membrane 100. In some embodiments, the central portion 126 includes a single opening 124 as discussed above. The opening 124 may be circular or ovate in shape, while in other embodiments, the opening 124 may be any solid shape, for example a square, triangle, hexagon or the like. In some embodiments, the central portion 126 may include multiple openings, as illustrated in B, for example a large opening 124 and a shaker opening 127. The shaker opening 127 may be configured to allow smaller amounts of the product to be dispensed at a time. In some embodiments, the central portion 126 may include a grid shaker 129, illustrated in I, wherein the grid shaker 129 is configured to declump the product while allowing more of the product through the shaker as compared to the sprinkle shaker 127. In some embodiments, the central portion 126 may include the extended opening 128.

The opening 124, shaker opening 127, or other openings may further be disposed within the peripheral zone 125 of the second layer 120. In some embodiments, the opening(s) may be disposed within the peripheral zone 125 and abut the second line of weakness 122, while in other embodiments, the openings may be disposed within the peripheral zone 125 only.

In some embodiments, the container 200 is configured to be used with the lid 205 in the closed configuration. In such embodiments, the lid 205 may be rotatably secured to the body 207 of the container 200. As illustrated in FIGS. 10A-C the lid 205 may include a port 214 covered by a seal 216. In some embodiments, the seal 216 may be a precut within the lid 205. The lid 205 may be removed from the body 207 of the container 200, to remove the flap 116 from the membrane 100. After the flap 116 is removed from the membrane 100, the lid 205 may be replaced onto the body of the container 200. Therein the opening 124, and the port 214 may define a channel connecting the internal body of the container 200 to the external surroundings. In some embodiments, the seal 216 may be resealable about the port 214.

The lid 205 may rotatably secured to the body 207 such that the port 214 may align with the opening 124 of the membrane 100, allowing a product to pass from the container 200 through the opening 124, and the port 214. In some embodiments, the lid 205 may be configured to be flush with the membrane 100 such that when the lid 205 is rotated to a closed position, (e.g., FIG. 10D) the lid 205 is configured to seal the membrane 100 to retain the contents within the container 200, and to keep the contents of the container 200 fresh. As illustrated in FIGS. 10D-F, the lid 205 may rotate either clockwise or counterclockwise from a closed position (e.g., FIG. 10D), to an open position (e.g., FIGS. 10E-F). The open position may align the opening 124 with the port 214 to allow dispensing of the contents of the container 200. The position of the port 214 on the opening 124 may influence the amount of product or the rate at which the product is dispensed from the container 200. For example, the port 214 may be positioned such that only a portion of the opening 124 is accessible (e.g., FIG. 10F) to provide a lower flow of the product, or such that the entire opening 124 is accessible (e.g., FIG. 10E) to provide a higher flow of the product (i.e. adjustable flow). Although only one opening 124 is illustrated, it should be understood that the second layer 120 may include a plurality of openings, or multiple openings as illustrated with reference to FIG. 9 .

In some embodiments, the lid 205 of the container 200 may be configured to interact with container bodies of varying heights. For example, the lid 205 may be configured for use with a first body 207 a defining a height of 70 mm, and a second body 207 b defining a height of 99 mm. In some embodiments, the body 207 of the container 200 may define a height of between 50-250 mm, between 55-250 mm, between 60-250 mm or in some embodiments between 45-300 mm. In some embodiments, the container 200 may define a volume of at least 95 ml. In some embodiments, the container 200 may define a volume of up to 250 ml. Although example container 200 sizes are described, it should be understood that any container 200 size may be used with the membrane 100.

In some embodiments, the lid 205 may be reusable. For example, a consumer may buy a starter container which includes the product sealed within the body 207 by the membrane 100, and a lid 205 to start. Then a user may buy containers which include the product within the body 207 sealed by the membrane 100, without the lid. The user may then take their existing lid 205 and use on the new container.

In some embodiments, the membrane 100 may be positioned on a rim of a container. FIGS. 11A-C illustrate a container 300 comprising a rim 330 circumscribed about at a top end 331 of a body 307 of the container 300. The rim 330 may be a rolled rim wherein a portion of the top end 331 is rolled towards an external surface 307 b of the body 307. The rim 330 may define a surface 330 a configured to receive and retain the membrane 100. In some embodiments, the rim 330 may define a larger diameter than the body 307.

In some embodiments, the peripheral area 115 of the membrane 100 may be adhered to the surface 330 a of the rim 330 with a permanent adhesive. The permanent adhesive may be applied to the bottom side of the first layer 110 of the membrane 100. In some embodiments, the adhesive is applied on to the surface 330 a of the rim 330 of the container 300.

In some embodiments, the membrane 100 may be flush with a bottom surface of a lid 305 when the lid 305 is applied to the container 300. In some embodiments, the lid 305 when applied to the top end 331 may create a seal over the opening 124 when the flap 116 is removed. In some embodiments, the flap 116 remains attached to the membrane 100 after opening. In such embodiments, replacement of the lid 305 onto the container 300 may aid in the reseal of the flap 116 to the peripheral zone 125 of the membrane 100.

In some embodiments, the membrane 100 may be configured to be recessed within the container 300, while being adhered about the rim 330 as illustrated in FIGS. 12A-D. FIG. 12A illustrates the container 300 within the lid 305 is configured as an overcap. The lid 305 may be configured to interact with the rim 330 of the body 307. FIG. 12B illustrates a cross-sectional view of the container 300 illustrating the membrane 100 recessed within the top end 331 of the body 307, such that the membrane 100 may be spaced apart from a bottom surface 305 a of the lid 305 when the lid is placed onto the body 307 of the container 300.

FIGS. 12C-D illustrate the peripheral area 115 of membrane 100 adhered about the rim 330 of the container 300. The peripheral area 115 of the first layer 110 extends from along an inner surface 330 a of the rim 330 to an outer surface 330 b of the rim 330. The first perimeter 111 of the membrane 100 may be positioned on the outer surface 330 b of the rim 330.

In some embodiments, the second layer 120 of the membrane 100 may abut an interior surface 307 a of the body 307, while in other embodiments, as illustrated in FIG. 12C the second layer 120 may not extend to the interior surface 307 a of the body 307.

In some embodiments, an adhesive extends from the outer surface 330 b of the rim 330 over the rim 330 onto the interior surface 330 a of the rim 330. In some embodiments, the membrane 100 may be adhered to the entirety of the outer surface 330 b of the rim 330, while in other embodiments, the membrane 100 may be adhered to a portion of the outer surface 330 b of the rim 330. In some embodiments, the adhesive may be applied to the top end 331 of the container 300, while in other embodiments, the adhesive may be applied to the peripheral area 115 of the first layer 110. The membrane 100 may be applied to the top end 331 after the application of the adhesive.

In some embodiments, the membrane 100 may be configured as the barrier between the contents of the container and the atmosphere. As illustrated in FIGS. 13A-D, a container 400 may be configured such that the membrane 100 may function as the lid of the container 400. As illustrated in FIG. 13A, the container system 400 includes a body 407 and a rim 433. The rim 433 may be formed to encompass a portion of the peripheral area 115. In some embodiments, the rim 433 may aid in securing the peripheral area 115 of the membrane to an interior surface 407 a of the body 407. In some embodiments, a through cut 119 may be formed within the pull tab 114. The through cut 119 may be circular, linear, triangular, or other shape configured to aid in moving the pull tab 114 from the plane of the membrane 100. In some embodiments, the pull tab 114 may be formed as part of or secured to the flap 116 prior to opening.

FIG. 13B illustrates a cross-sectional view of the container system 400. As illustrated the rim 433 and the body 407 are formed from a continuous piece of material. The rim 433 may be rotated inward (e.g., towards the center axis of the body 207) until the material reaches the interior surface 407 a of the body 407. In some embodiments, the rim 430 is folded to define an angle of up to 90 degrees with the interior surface 407 a, an angle of up to 70 degrees with the interior surface 407 a, or up to 45 degrees with the interior surface 407 a of the body 407. In some embodiments, the rim top end 431 of the body 407 may be folded, rolled, creased, curled, crimped, or similar to form the rim 433.

In some embodiments, the rim 433 may be in contact with the membrane 100, while in other embodiments, the end 433 a of the rim 433 may not be in contact with the membrane 100.

In some embodiments, a portion of the peripheral area 115 may be disposed interior to the rim 433. In some embodiments, the top end 431 may be folded in towards the interior surface 407 a of the body 407. In some embodiments, the curled rim 433 may fold such that the curled 433 is in contact with the membrane 100.

In some embodiments, illustrated in FIG. 13C the first line of weakness 112 may separate or fracture upon maneuvering the pull tab 114. The first line of weakness 112 may open or rupture, thereby providing access to the opening within the central portion 126. In some embodiments, the flap 116 may be replaced on the peripheral zone 125 of the second layer 120. An edge 112 c of the pull tab 114, illustrated in FIG. 13D may be manually positioned under the rim 433 to resecure the flap 116 in the plane of the membrane 100. In some embodiments, the pull tab may extend from the crease 117 to the first perimeter 111. In some embodiments, the flap 116 may define varying diameters. In some embodiments, the flap may define a pull tab diameter D₂′, extending from the edge of the pull tab 114 across the flap 116. The flap may define a second diameter D₂ extending perpendicular to the pull tab diameter D₂′. The pull tab diameter D₂′ may be larger than the second diameter D₂ such that the pull tab 114 is configured to extend further into the peripheral area 115, to be positioned under the rim 433 of the body 407. In an embodiment, the pull tab 114 is sized such that it extends slightly beyond the rim 433 when extended. In this embodiment, the pull tab 114 can be tucked beneath the rim 433 in a reclosed position of the flap 116.

In some embodiments, the through cut 119 may be used to insert a finger into and maneuver the pull tab 114 out from under the rim 433 to again reopen the flap 116 to provide access to the contents of the container 400. This process may be repeatable any number of times to provide a reclose function to the container system.

In some embodiments, the peripheral area 115 of the membrane 100 may be adhered to the interior surface 407 a with a permanent adhesive. In some embodiments, the membrane 100 may be adhered to the entire top end 431 of the body 407 such that a portion of the peripheral area 115 is within the rim 433.

In an embodiment, the membrane 100 may be formed in an in-line process. In some embodiments, the container 400, may be formed at the time of filling. To explain, in some embodiments, the container 400 may be die cut and laid flat. In some embodiments, a portion of the membrane 100 may be adhered to a portion of the interior surface of the unformed container. The container may be shaped into a tubular shape and filled. After the product is added into the container the membrane 100 may be fully attached about the interior surface of the container. Upon attachment of the membrane the top end of the body may be rolled, knurled or shaped to maintain the membrane within the container.

In some embodiments, the membrane 100 may be applied and used with other types of containers. FIGS. 14A-D, illustrate an example container 500 defining at least one cavity 511 having a flange 533 surrounding the cavity 511. In some embodiments, the membrane 100 may be adhered to the flange 533 with a permanent adhesive. In some embodiments, a body 507 may define the cavity 511, and in some embodiments, the body 507 may define a plurality of cavities 511.

In some embodiments, the web of membranes may be formed by supplying the first layer 110 as a web of paper and forming the first line of weakness 112, crease, and the pull tab 114 within the first layer 110. The second layer 120 may be formed as individual components to be attached to the first layer 110, in an alternative embodiment, the second layer 120 may be formed as a web and adhered to the first layer 110. After formation of the web of membranes 100′ the web 100′ may be adhered to the flange 533 of the body 507.

In some embodiments, a web of membranes 100′ may be formed to correspond to the number of cavities 511 within the body 507 of the container 500. The web of membranes 100′ may be formed with the same layers and cuts as the membrane 100 described with respect to FIGS. 1A-B. In some embodiments, as illustrated in FIG. 13A, the body 507 may define two cavities, and have a web of membranes 100′ defining two sealing systems (e.g., pull tab 114, flap 116, second layers 220).

In some embodiments, illustrated in FIG. 14B, the body 507 may define two or more distinct cavities 511. In some embodiments, the body 507 may be formed as a sheet of cavities 511 to be filled sealed, and then the cavities may be divided into individual containers, by severing along the flange 533.

In some embodiments, the container system described herein may contain and dispense seasonings, spices, bite-sized snacks, gum, candy, salt, sugar, milk powder, infant formula, ground coffee, coffee beans, dietary supplements, dry sauce bases, dried tobacco or any other similar product.

Many modifications and other embodiments of the present disclosure set forth herein will come to mind to one skilled in the art to which the present disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the present disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

What is claimed is:
 1. A membrane for use with a container, the membrane comprising: a first layer comprising a peripheral area, wherein the peripheral area is defined by a first perimeter of the first layer, and a first line of weakness formed inward of the first perimeter, wherein the first line of weakness defines a flap; and a second layer comprising a peripheral zone, wherein the peripheral zone is defined by a second perimeter of the second layer and a second line of weakness formed inward of the second perimeter, wherein the second line of weakness defines a central portion; and a first seal area, wherein at least a portion of the peripheral zone of the second layer is adhered to at least a portion of the peripheral area of the first layer in the first seal area.
 2. The membrane of claim 1, wherein the first layer defines a first shape and the second layer defines a second shape, wherein the first shape and the second shape are the same.
 3. The membrane of claim 1, wherein the first layer and the second layer are formed from one of paper or cardboard.
 4. The membrane of claim 1, further comprising a hinge formed within the first line of weakness.
 5. The membrane of claim 1, wherein the seal area forms a hermetic seal between the first layer and the second layer.
 6. The membrane of claim 1, wherein the first seal area is disposed between the perimeter of the first layer and the first line of weakness of the first layer.
 7. The membrane of claim 1, wherein the first seal area is disposed between the second perimeter of the second layer and the first line of weakness.
 8. The membrane of claim 1, additionally comprising a second seal area, wherein the second seal area is disposed between the second line of weakness of the second layer and the first line of weakness of the first layer.
 9. The membrane of claim 8, wherein the second seal area comprises a peelable adhesive.
 10. The membrane of claim 8, wherein the second seal area comprises a pressure sensitive adhesive.
 11. The membrane of claim 8, wherein the first seal area comprises a permanent adhesive.
 12. The membrane of claim 8, wherein the first seal area and the second seal area are formed with the same type of adhesive.
 13. The membrane of claim 8, wherein the first seal area and the second seal area are formed with different adhesives.
 14. The membrane of claim 1, wherein the flap of the first layer further comprises a pull tab.
 15. The membrane of claim 14, wherein the pull tab comprises a portion of the flap which is folded and configured to extend out of the plane of the first layer.
 16. The membrane of claim 1, wherein the flap is resealable to the peripheral zone.
 17. The membrane of claim 1, wherein the second layer further comprises at least one opening disposed within the central portion.
 18. The membrane of claim 17, wherein the at least one opening comprises a plurality of openings.
 19. The membrane of claim 17, wherein the at least one opening is a first opening and a second opening, wherein the first opening and the second opening are different sizes.
 20. A package comprising: a body defining a top end and an internal wall; a lid configured to be received by the top end of the body; and a membrane adhered to the body, wherein the membrane comprises: a first layer comprising a peripheral area, wherein the peripheral area is defined by a first perimeter of the first layer, and a first line of weakness formed inward of the first perimeter, wherein the first line of weakness defines a flap; and a second layer comprising a peripheral zone, wherein the peripheral zone is defined by a second perimeter of the second layer and a second line of weakness formed inward of the second perimeter, wherein the second line of weakness defines a central portion, wherein the central portion comprises an opening; and a first seal area, wherein at least a portion of the peripheral zone of the second layer is adhered to at least a portion of the peripheral area of the first layer in the first seal area.
 21. The package of claim 20, wherein at least the first layer of the membrane is recessed within the internal wall.
 22. The package of claim 20, wherein the internal wall further comprises an inner liner, sealant layer or coating.
 23. The package of claim 20, wherein the seal area forms a hermetic seal between the first layer and the second layer.
 24. The package of claim 20, wherein the membrane is adhered to the internal wall of the body.
 25. The package of claim 20, wherein the membrane is adhered to a rim circumscribing the top end of the body.
 26. The package of claim 20, wherein the lid is hingedly attached to the body.
 27. The package of claim 20, wherein the lid is rotatably attached to the body.
 28. The package of claim 27, wherein the lid comprises a port, such that when rotated the port aligns with the opening in the second layer of the membrane.
 29. A package comprising: a body defining a top end; and a membrane adhered to an inner surface of the body, wherein the membrane comprises: a first layer comprising a peripheral area, wherein the peripheral area is defined by a first perimeter of the first layer, and a first line of weakness formed inward of the first perimeter, wherein the first line of weakness defines a flap; and a second layer comprising a peripheral zone, wherein the peripheral zone is defined by a second perimeter of the second layer and a second line of weakness formed inward of the second perimeter, wherein the second line of weakness defines a central portion, wherein the central portion comprises an opening; and a first seal area, wherein at least a portion of the peripheral zone of the second layer is adhered to at least a portion of the peripheral area of the first layer in the first seal area.
 30. The package of claim 29, wherein the top end of the body is folded inward, toward a central axis of the body, to form a rim.
 31. The package of claim 30, wherein the flap comprises a pull tab configured to tuck under the rim of the body in a reclosed position of the flap.
 32. The package of claim 30, wherein the pull tab comprises a through cut sized and configured to receive a finger for opening of the flap. 